SLUU885C March   2012  – June 2024 UCD3138 , UCD3138064 , UCD3138064A , UCD3138128 , UCD3138A , UCD3138A64

 

  1.   1
  2.   2
  3.   Abstract
  4. 1 Introduction
  5. 2 Description
    1. 2.1 Typical Applications
    2. 2.2 Features
  6. 3 Electrical Performance Specifications
  7. 4 Schematics
  8. 5 Test Setup
    1. 5.1 Test Equipment
    2. 5.2 Recommended Test Setup
  9. 6 List of Test Points
  10. 7 List of Terminals
  11. 8 Test Procedure
    1. 8.1 Efficiency Measurement Procedure
    2. 8.2 Equipment Shutdown
  12. 9 Performance Data and Typical Characteristic Curves
    1. 9.1 Efficiency
    2. 9.2 Power Factor
    3. 9.3 Total Harmonic Distortion (THD)
    4. 9.4 Input Current at 230 VAC and 50 Hz
    5. 9.5 Output Voltage Ripple
    6. 9.6 Output Turn On
    7. 9.7 Total Harmonic Distortion (THD)
    8. 9.8 Other Waveforms
  13. 10EVM Assembly Drawing and PCB Layout
  14. 11List of Materials
  15. 12Digital PFC Description
    1. 12.1  1PFC Block Diagram
      1. 12.1.1 Single-Phase PFC Block Diagram
      2. 12.1.2 2-Phase PFC Block Diagram
      3. 12.1.3 Bridgeless PFC Block Diagram
    2. 12.2  UCD3138 Pin Definition
      1. 12.2.1 UCD3138 Pin Definition in Single-Phase PFC
      2. 12.2.2 UCD3138 Pin Definition in 2-Phase PFC
      3. 12.2.3 UCD3138 Pin Definition in Bridgeless PFC
    3. 12.3  EVM Hardware – Introduction
      1. 12.3.1 PFC Pre-Regulator Input
      2. 12.3.2 PFC Power Stage
      3. 12.3.3 Non-Isolated UART Interface
      4. 12.3.4 Isolated UART Interface
      5. 12.3.5 Interface Connector of Control Card
      6. 12.3.6 UCD3138 Resource Allocation for PFC Control
    4. 12.4  EVM Firmware – Introduction
      1. 12.4.1 Background Loop
      2. 12.4.2 Voltage Loop Configuration
      3. 12.4.3 Current Loop Configuration
      4. 12.4.4 Interrupts
    5. 12.5  State Machine
    6. 12.6  PFC Control Firmware
    7. 12.7  System Protection
      1. 12.7.1 Cycle-by-Cycle Current Protection (CBC)
      2. 12.7.2 Over-Voltage Protection (OVP)
    8. 12.8  PFC System Control
      1. 12.8.1 Average Current Mode Control
      2. 12.8.2 ZVS and Valley Control
    9. 12.9  Current Feedback Control Compensation Using PID Control
      1. 12.9.1 Loop Compensation from Poles and Zeros in s-Domain
      2. 12.9.2 Feedback Loop Compenstaion Tuning with PID Coefficients
      3. 12.9.3 Feedback Loop Compensation with Multiple-Set of Parameters
    10. 12.10 Voltage Feedback Loop
  16. 13Evaluating the Single-Phase PFC with GUI
    1. 13.1 Graphical User Interface (GUI)
    2. 13.2 Open the Designer GUI
    3. 13.3 Overview of the Designer GUI
      1. 13.3.1 Monitor
      2. 13.3.2 Status
      3. 13.3.3 Design and Configure
  17. 14Monitoring, Re-configuring and Re-tuning with Designer GUI
    1. 14.1 Power On and Test Procedure
    2. 14.2 Monitoring with GUI
    3. 14.3 Configuration and Re-configuring with GUI
    4. 14.4 Feedback Control Loop Tuning and Re-Tuning with GUI
      1. 14.4.1 Current Loop Evaluation
      2. 14.4.2 Current Loop Re-Tuning
      3. 14.4.3 Voltage Loop Evaluation and Re-tuning
  18. 15Digital PFC Firmware Development
  19. 16References
  20. 17Revision History

11 List of Materials

The List of Materials is Based on Figure 4-1 and Figure 4-2.

Table 11-1 UCD3138PFCEVM-026 List of Materials
QTY REF DES DESCRIPTION PART NUMBER MFR
1 C1 Capacitor, tantalum, 25 V, 20%, 10 µF, 3528 TPSB106M025R1800 AVX
0 C10, C11 Capacitor, ceramic, 50 V, X7R, 10%, open, 1206 Std Std
2 C12, C20 Capacitor, ceramic, 50 V, X7R, 10%, 1 nF, 0805 Std Std
1 C16 Capacitor, ceramic, 50 V, X7R, 10%, 0.01 µF, 0805 Std Std
0 C17, C25, C29 Capacitor, ceramic, 50 V, X7R, 10%, open, 0805 Std Std
2 C2, C3 Capacitor, metalized polyester, 250 VAC, ±20%, 47 nF, 0.472 inch x 0.925 inch ECQ-U2A473MV Panasonic
1 C21 Capacitor, tantalum, 10 V, 20%, 10 µF, 3216 TAJA106M010RNJ AVX
1 C22 Capacitor, film, 300 VAC, ±20%, 47 nF, 0.236 inch x 0.591 inch ECQ-U3A473MG Panasonic
1 C26 Capacitor, ceramic, 50 V, X7R, 10%, 1 µF, 0805 Std Std
1 C30 Capacitor, ceramic, 50 V, X7R, 10%, 330 pF, 0805 Std Std
1 C31 Capacitor, tantalum chip, 16 V, 47 µF, 0.281 inch x 0.126 inch 595D476X9016C2T Vishay
1 C32 Capacitor, ceramic, 50 V, NP0, 5%, 150 pF, 0805 Std Std
4 C33, C39, C40, C41 Capacitor, polyester, 630 V, 10%, 47 nF, 0.256 inch x 0.650 inch ECQ-E6473KF Panasonic
1 C34 Capacitor, aluminum electrolytic, 450 VDC, -40°C to 85°C, ±20%, 220 µF, 0.984 inch diameter ECOS2WP221CX Panasonic
2 C35, C36 Capacitor, ceramic, 50 V, X7R, 10%, 100 pF, 0603 Std Std
2 C37, C38 Capacitor, film, 275 VAC, ±20%, 0.47 µF, 0.236 inch x 0.591 inch ECQU2A474ML Panasonic
7 C4, C18, C19, C23, C24, C27, C28 Capacitor, ceramic, 50 V, X7R, 10%, 0.1 µF, 0805 Std Std
3 C5, C6, C7 Capacitor, metalized polyester, 250 VAC, ±20%, 4.7 nF, 0.295 inch x 0.730 inch BFC233820472 Vishay
5 C8, C9, C13, C14, C15 Capacitor, ceramic, 50 V, X7R, 10%, 0.1 µF, 0603 Std TDK
9 D1, D2, D3, D4, D6, D15, D22, D23, D25 Diode, dual Schottky, 200 mA, 30 V, SOT23 BAT54S Zetex
2 D11, D12, D24 Diode, Schottky, 500 mA, 30 V, SOD123 MBR0530T1G On Semi
2 D13, D14 Diode, Schottky rectifier, 10 A, 600 V, TO-263-2 C3D10060G CREE
1 D16 Diode, 600 V, 6 A, 400 A peak surge, P600 6A6-T Diodes
1 D17 Diode, bridge rectifier, 8 A, 600 V, 0.880 inch x 0.140 inch GBU8J Fairchild
1 D18 Diode, LED, green, 2.1 V, 20 mA, 6 mcd, 0603 LTST-C190GKT Lite On
1 D19 Diode, LED, green, 2.1 V, 20 mA, 0.9 mcd, 0.068 inch x 0.049 inch LN1371GTR Panasonic
1 D20 Diode, LED, red, 2.1 V, 20 mA, 6 mcd, 0603 LTST-C190CKT Lite On
1 D21 Diode, LED, yellow, 2.1 V, 20 mA, 6 mcd, 0603 LTST-C190YKT Lite On
1 D5 Diode, signal, 300 mA, 75 V, 350 mW, SOD-123 1N4148W-TP MICROSEMI
1 D7 Diode, ultrafast rectifier, 1 A, 200 V, SMB MURS160T3G On Semi
1 D8 Diode, dual Schottky, 200 mA, 30 V, SOT-23 BAT54C Fairchild
2 D9, D10 Diode, Schottky, 500 mA, 60 V, SOT-23 ZHCS506 Zetex
1 DB-1 Module, 5 W, auxiliary bias PS, PCB assembly, 1.200 inch x 2.200 inch PWR050(1) TI
1 DB-2 Control card, UCD3138 control card, PCB assembly, 3.400 inch x 1.800 inch UCD3138CCEVM-030 TI
1 F1 Fuse, 250 VAC, SLO-BLO, 3 AG, 7-A cart, 0.250 inch x 1.250 inch 0313007.HXP Littlefuse
1 F2 Ffuse holder, 1/4 inch, board mount, 1.54 inch x 0.30 inch BK/1A3398-07 Bussmann
1 HS1 Heatsink, TO-220, vertical mount, 15 x C/W, 0.5 inch x 0.95 inch 593002B00000G Aavid
2 HS2, HS3 Heatsink, TO-220, vertical mount, 5 x C/W, 0.5 inch x 1.38 inch 513201 Aavid
5 J1, J2, J5, J6, J11 Terminal block, 2 pin, 15 A, 5.1 mm, 0.40 inch x 0.35 inch ED120/2DS OST
1 J10 Header, male 3 pin, 100-mil spacing, 0.100 inch x 3 inch PEC03SAAN Sullins
2 J3, J4 Header, 40 pin, 2 mm pitch, 4.00 mm x 40.00 mm 87758-4016 Molex
1 J7 Terminal block, 2 pin, 6 A, 3.5 mm, 0.27 inch x 0.25 inch ED555/2DS OST
1 J8 Header, male 2 x 3 pin, 100-mil spacing, 0.20 inch x 0.30 inch PEC03DAAN Sullins
1 J9 Connector, 9-pin D, right angle, female, 1.213 inch x 0.510 inch 182-009-213R171 Norcomp
1 JMP1 Jumper, 0.400 inch length, bare, solid, bus-bar wire, AWG 16, 0.051 inch 295 SV005 ALPHA WIRE
1 K1 Relay, SPDT, 10-A miniature, 12-V coil, 0.630 inch x 0.870 inch T7NS5D1-12 Tyco
2 L1, L2 Inductor, toroid, 327 µH, vertical THT, 327 µH, 0.866 inch x 1.380 inch 7804-09-0014 Nova Magnetics
2 L3, L4 Inductor, toroid, 7.8 µH at 0 A and 3.22 µH at 20.5 A, 7.80 µH, 0.874 inch x 0.374 inch PA0431L Pulse
1 L5 IND, common mode emi suppression, 7.5 A, 2 mH at 1 kHz, 2 mH, 0.800 inch x 1.440 inch PE-62917 Pulse
3 Q1, Q4, Q5 MOSFET, N-channel, 60 V, 115 mA, 1.2 Ω, SOT23 2N7002 Fairchild
2 Q2, Q3 MOSFET, N-channel, 650 V, 9 A, 199 mΩ, TO-220V IPP60R199CP Infineon
3 Q6, Q7, Q8 Bipolar, NPN, 40 V, 200 mA, 200 mW, SC-75 MMBT3904TT1G On Semi
0 R1, R24, R40, R43, R68 Resistor, chip, 1/10 W, 1%, open, 0805 Std Std
6 R13, R15, R27, R28, R29, R30 Resistor, chip, 1/4 W, 1%, 200 kΩ, 1210 Std Std
2 R14, R16 Resistor, chip, 1/4 W, 1%, 3.83 kΩ, 1210 Std Std
4 R19, R20, R21, R22 Resistor, chip, 1/10 W, 1%, 4.7 kΩ, 0805 Std Std
1 R2 Resistor, chip, 1/10 W, 1%, 3.3 MΩ, 0805 Std Std
1 R23 Resistor, chip, 1/10 W, 1%, 3.3 kΩ, 0805 Std Std
1 R3 Resistor, wire-wound, 5 W, 5%, 50 Ω, 1.000 inch x 0.276 inch 25J50RE Ohmite
2 R31, R72 Resistor, chip, 1/4 W, 1%, 1.5 kΩ, 1210 Std Std
9 R32, R41, R44, R49, R52, R54, R75, R76, R77 Resistor, chip, 1/10 W, 1%, 0 Ω, 0805 Std Std
2 R33, R35 Resistor, chip, 1/4 W, 1%, 0 Ω, 1210 Std Std
0 R34, R36 Resistor, chip, 1/4 W, 1%, open, 1210 Std Std
7 R37, R38, R56, R57, R70, R73, R74 Resistor, chip, 1/10 W, 1%, 10 kΩ, 0805 Std Std
2 R39, R58 Resistor, chip, 1/10 W, 1%, 2 kΩ, 0805 Std Std
1 R4 Resistor, chip, 1/10 W, 1%, 5.01 kΩ, 0805 Std Std
2 R45, R79 Resistor, chip, 1/10 W, 1%, 100 Ω, 0805 Std Std
3 R47, R48, R50 Resistor, chip, 1/10 W, 1%, 1.8 kΩ, 0805 Std Std
7 R5, R8, R42, R61, R80, R81, R82 Resistor, chip, 1/10 W, 1%, 1 kΩ, 0805 Std Std
2 R53, R55 Resistor, chip, 1/10 W, 1%, 5.23 Ω, 0805 Std std
2 R59, R60 Resistor, chip, 1/10 W, 1%, 49.9 kΩ, 0805 Std Std
2 R6, R7 Resistor, metal strip, 2 W, 1%, 0.02 Ω, 0.49 inch x 0.10 inch WSR2R0200FEA Vishay Dale
2 R63, R66 Resistor, chip, 1/10 W, 1%, 15 Ω, 0805 Std Std
2 R64, R65 Resistor, chip, 1/10 W, 1%, 10 kΩ, 1206 Std std
1 R69 Resistor, chip, 1/10 W, 1%, 1.6 kΩ, 0805 Std Std
1 R71 Resistor, chip, 1/10 W, 1%, 910 Ω, 0805 Std Std
1 R78 Resistor, chip, 1/10 W, 1%, 1.1 kΩ, 0805 Std Std
12 R9, R10, R11, R12, R17, R18, R25, R26, R46, R51, R62, R67 Resistor, metal film, 1/4 W, ±5%, 100 kΩ, 1206 RC1206FR-07100KL Yageo
2 U1, U3 High Voltage, High Current Op-Amp, MSOP-8 OPA350EA/250 TI
1 U2 RS-232 Transceivers with Auto Shutdown, SSOP-16 SN75C3221DBR TI
2 U4 High-Speed Low-Side Power MOSFET driver, SO8 UCC27324D TI
0 U5, U6 4-A Single Channel High-Speed Low-Side Gate Drivers, open, SOT23-6 UCC27517DBV TI
1 U7 3.3-V, 800-mA LDO Voltage Regulators, SOT-223 TLV1117-33IDCY TI
1 U8 Digital Isolators, xx Mbps, SO-8 ISO7221CD TI
1 U9 Opto-coupler, SMD-4P SFH6156-2 Vishay
(1) PWR050 is a bias board and its design documents can be found at www.ti.com in the UCD3138PFCEVM026 Technical Documents section.